Composite yarn

ABSTRACT

Provided is a composite yarn. The composite yarn includes a core and a sheath. The core is made of a thermoplastic material; wherein the thermoplastic material is selected from a group consisting of: a polyester, a polyamide, a polyacrylonitrile and any combination thereof. The sheath formed around the core is made of a cladding material, and the cladding material comprises polyvinyl butyral; wherein the polyvinyl butyral has a melt flow rate ranging from 2 g/10 min to 35 g/10 min; the melt flow rate is measured by a standard method ASTM D1238 at 190° C. with 2.16 kg load.

CROSS-REFERENCE TO RELATED APPLICATION

Pursuant to 35 U.S.C. § 119(a), this application claims the benefit of the priority to Taiwan Utility Model Application No. 109202337, filed on Mar. 3, 2020. The content of the prior application is incorporated herein by its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to a composite yarn, and more particular to a core-sheath type composite yarn.

2. Description of the Prior Arts

Conventionally, after a fabric is obtained by weaving with yarns, the whole fabric needs to be subjected to a sizing step or a sticking step at junctions of multiple crossing yarns by a thermoplastic material. After that, the fabric can be subjected to a setting step. However, the above-mentioned process makes the sizing and setting steps more complicated, and characteristics of the resulting fabric will be easily affected. For example, the resulting fabric may be stiff, and the touch of the resulting fabric or the morphology of the resulting fabric may be affected. Further, the thermoplastic material used in the art generally is polyvinyl chloride (PVC), which is toxic and cannot meet the requirements of environmental protection. It can be seen that yarns or the sizing and setting steps after weaving still need to be developed and improved continuously.

Compared with PVC, which cannot meet the requirements of environmental protection, polyvinyl butyral (PVB) is a more eco-friendly material. Besides, PVB can be obtained by recycling wasted laminated safety glass; thus, the recycled PVB can meet the requirements of environmental protection and conform to the business model of circular economy. In view of that, if the recycled PVB is applied to a yarn production or the sizing and setting steps after weaving, the defects of the conventional textile manufacturing should be overcome promisingly.

SUMMARY OF THE INVENTION

An objective of the instant disclosure is to provide a composite yarn, which is beneficial for setting and reinforcing an obtained fabric comprising the same and meets the requirements of environmental protection.

The instant disclosure provides a composite yarn. The composite yarn includes a core and a sheath. The core is made of a thermoplastic material; wherein the thermoplastic material is selected from a group consisting of: a polyester, a polyamide, a polyacrylonitrile and any combination thereof. The sheath, which is formed around the core, is made of a cladding material, and the cladding material comprises PVB; wherein the PVB has a melt flow rate (MFR) ranging from 2 grams per 10 minutes (g/10 min) to 35 g/10 min. The MFR is measured by a standard method ASTM D1238 at 190° C. with 2.16 kilograms (kg) load.

Since the sheath of the composite yarn fully wraps the core, and the sheath is composed of the cladding material comprising PVB, when the composite yarn is subsequently used in manufacture of fabrics, the sheath will help the direct set of the obtained fabrics through a hot-melt step. Thus, a necessary setting step by using a glue or an adhesive film in the conventional process is no longer needed and textile manufacturing will be simplified. In addition, in the cladding material of the instant disclosure, PVB is used to replace PVC, so the composite yarn can meet the requirements of eco-friendliness. Moreover, by controlling the MFR of the PVB of the instant disclosure within a specific range, the PVB will have a suitable flowability during a hot-melt step. Therefore, even though the cladding material does not comprise any plasticizer, the cladding material still can make the surface of the obtained fabric smooth and make the touch of the obtained fabric comfortable.

Preferably, the cladding material may further comprise a polymer material. Specifically, the polymer material may comprise a phenol-formaldehyde resin, an epoxy resin, a thermoplastic polyurethane (TPU), a poly(methyl methacrylate), an ethylene-vinyl acetate copolymer (EVA), a methyl methacrylate-butadiene-styrene copolymer (MBS), a styrene-butadiene block copolymer (SBC) or any combination thereof.

More preferably, the polymer material may be the TPU. When the cladding material comprises the TPU, the cladding material can further adjust the elasticity thereof. In an embodiment, the TPU is in an amount from larger than 0 part by weight to 100 parts by weight relative to 100 parts by weight of the PVB.

Preferably, the cladding material may further comprise a plasticizer. Specifically, the plasticizer may comprise acetyl tributyl citrate (ATBC), acetyl trioctyl citrate (ATOC), an alkyl benzyl phthalate such as butyl benzyl phthalate, an alkyl phthalate, blown linseed oil, butyl ricinoleate, castor oil, a dialkyl adipate such as dihexyl adipate and dioctyl adipate (DOA), a dialkyl phthalate such as dibutyl phthalate (DBP) and dioctyl phthalate (DOP), di-isononyl-cyclohexane-dicarboxylate (DINCH), ethylene glycol di-N-butyrate, isodecyl diphenyl phosphate, N-ethyl toluenesulfonamide, polyethylene glycol, tert-butylphenyl diphenyl phosphate, toluenesulfonamide, triaryl phosphate ester blend, tributyl citrate (TBC), tricresyl phosphate (TCP), triethyl citrate (TEC), triethylene glycol, triethylene glycol bis(2-ethylhexanoate), triphenyl phosphate (TPP), 2-ethylhexyl diphenyl phosphate or any combination thereof.

In certain embodiments, the plasticizer is in an amount from 20 parts by weight to 100 parts by weight relative to 100 parts by weight of the PVB.

Preferably, the PVB may be obtained by recycling wasted laminated safety glass. In particular, the process of producing the recycled PVB from the wasted laminated safety glass contains a separation procedure and a purification procedure. The separation procedure may comprise steps in sequence: cutting edges of the wasted laminated safety glass that are adhered to impurities, crushing the aforesaid wasted laminated safety glass, soaking the original PVB layer of the aforesaid wasted laminated safety glass, and striking the aforesaid wasted laminated safety glass to make the glass fall off. The purification procedure may comprise steps in sequence: tearing the aforesaid PVB layer, further removing remaining glass, adding magnesium silicate and then drying at 45° C., and finally obtaining the recycled PVB.

Preferably, the PVB has the MFR ranging from 7 g/10 min to 15 g/10 min.

Preferably, the sheath has a thickness ranging from 0.08 millimeters (mm) to 5.0 mm More preferably, the sheath has the thickness ranging from 0.08 mm to 0.9 mm. The thickness of the sheath is a distance defined as a difference between a radius of the composite yarn and a radius of the core.

In accordance with the instant disclosure, the core may be a single yarn or a strand. The single yarn with a certain strength and a certain density is produced by two or more staple fibers or filaments which are arranged almost in parallel and then are twisted helically along an axial direction. The strand is composed of two or more single yarns twisted together. Both of the aforesaid single yarn and the aforesaid strand are made of the thermoplastic material.

In accordance with the instant disclosure, the composite yarn can be used to produce a fabric by knitting, circular weaving, plain weaving or weaving, but it is not limited thereto.

In accordance with the instant disclosure, the fabric produced by the composite yarn can be applied for various purposes such as curtains, carpets, awnings, beach umbrellas, table mats and mobile phone bags, but it is not limited thereto.

Other objectives, advantages and novel features of the disclosure will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The sole FIGURE is a structural schematic view showing that a composite yarn of one preferable example in accordance with the instant disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, one skilled in the arts can easily realize the advantages and effects of the instant disclosure from the following example. Therefore, it should be understood that the descriptions proposed herein are just preferable examples for the purpose of illustrations only, not intended to limit the scope of the disclosure. Various modifications and variations could be made in order to practice or apply the instant disclosure without departing from the spirit and scope of the disclosure.

The preferred embodiment of the instant disclosure will hereinafter be described in conjunction with the appended drawing, provided to illustrate the technical means adopted to achieve the objective of the instant disclosure.

With reference to the sole FIGURE, a composite yarn 1 of Example 1 of the instant disclosure comprised a core 10 and a sheath 20.

The core 10 was a single yarn made by twisting multiple polyamide filaments.

The sheath 20 was wrapped around the core 10. The sheath 20 was composed of a cladding material, which comprised PVB and a plasticizer. Provided that the PVB was in an amount of 100 parts by weight, the plasticizer was in an amount of 20 parts by weight.

The PVB had a melt flow rate of 12 g/10 min according to a standard method ASTM D1238 at 190° C. with 2.16 kg load.

The PVB was obtained by recycling wasted laminated safety glass.

The sheath 20 had a thickness of 0.25 mm.

In conclusion, the sheath of the composite yarn of the instant disclosure is fully wrapped around the core and the sheath is composed of the cladding material comprising PVB, so the sheath can make an obtained fabric set directly through a hot-melt process when the composite yarn is used in subsequent manufacture of fabrics. Therefore, the textile manufacturing will be simplified. In addition, the cladding material is essentially composed of PVB, which can sufficiently meet the requirements of environmental protection, so the composite yarn indeed can achieve the objective of the instant disclosure.

Even though numerous characteristics and advantages of the instant disclosure have been set forth in the foregoing description, together with details of the structure and features of the disclosure, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

What is claimed is:
 1. A composite yarn, comprising: a core which is made of a thermoplastic material; wherein the thermoplastic material is selected from a group consisting of: a polyester, a polyamide, a polyacrylonitrile and any combination thereof; and a sheath which is formed around the core; wherein the sheath is made of a cladding material, and the cladding material comprises polyvinyl butyral; wherein the polyvinyl butyral has a melt flow rate ranging from 2 grams per 10 minutes to 35 grams per 10 minutes; the melt flow rate is measured by a standard method ASTM D1238 at 190° C. with 2.16 kilograms load.
 2. The composite yarn as claimed in claim 1, wherein the sheath has a thickness ranging from 0.08 millimeters to 5.0 millimeters.
 3. The composite yarn as claimed in claim 1, wherein the sheath has a thickness ranging from 0.08 millimeters to 0.9 millimeters.
 4. The composite yarn as claimed in claim 1, wherein the cladding material further comprises a thermoplastic polyurethane.
 5. The composite yarn as claimed in claim 4, wherein the thermoplastic polyurethane is in an amount from larger than 0 part by weight to 100 parts by weight relative to 100 parts by weight of the polyvinyl butyral.
 6. The composite yarn as claimed in claim 1, wherein the cladding material further comprises a plasticizer.
 7. The composite yarn as claimed in claim 6, wherein the plasticizer is in an amount from 20 parts by weight to 100 parts by weight relative to 100 parts by weight of the polyvinyl butyral.
 8. The composite yarn as claimed in claim 4, wherein the cladding material further comprises a plasticizer.
 9. The composite yarn as claimed in claim 8, wherein the plasticizer is in an amount from 20 parts by weight to 100 parts by weight relative to 100 parts by weight of the polyvinyl butyral.
 10. The composite yarn as claimed in claim 1, wherein the polyvinyl butyral has the melt flow rate ranging from 7 grams per 10 minutes to 15 grams per 10 minutes; the melt flow rate is measured by the standard method ASTM D1238 at 190° C. with 2.16 kilograms load.
 11. The composite yarn as claimed in claim 6, wherein the polyvinyl butyral has the melt flow rate ranging from 7 grams per 10 minutes to 15 grams per 10 minutes; the melt flow rate is measured by the standard method ASTM D1238 at 190° C. with 2.16 kilograms load.
 12. The composite yarn as claimed in claim 7, wherein the polyvinyl butyral has the melt flow rate ranging from 7 grams per 10 minutes to 15 grams per 10 minutes; the melt flow rate is measured by the standard method ASTM D1238 at 190° C. with 2.16 kilograms load. 